2005-2008 KTM 250 SX-F, EXC-F, XC-F, XCF-W, SXS-F Engine Repair Manual

Full service and repair documentation for KTM 250 SX-F, EXC-F, XC-F, XCF-W, SXS-F models (2005-2008). Includes engine overhauls, component servicing, and troubleshooting. PN 3.206.052-E.

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Document Details

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Document Number / Seller:
31031 / Laura Stewart
File Size:
7.98 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Engines (Gasoline)
Last updated / verified
Sep 21, 2025

Models Covered & Key Technical Specifications

KTM 250 SX-F, EXC-F, XC-F, XCF-W, SXS-F (Engine) Repair Manual (2005-2008) - Art.Nr. 3.206.052-E

This workshop manual covers engine repairs for the specified KTM models. | Engine Repository

  • Engine Specifications: Displacement: 249.51 ccm provides the core engine size.
  • Valve Clearance Data: Intake valves: 0.10 - 0.20 mm ensures optimal engine breathing.
  • Ignition System Type: Contactless DC-CDI ignition offers reliable spark.
  • Oil Capacity Details: 1.1 liters of full synthetic oil is required for lubrication.
  • Transmission Type: 6-speed claw shifted transmission for versatile gear selection.
  • Cooling System Method: Liquid-cooled, permanent rotation system for efficient heat management.

Professional Workshop Service Manual & Technical Specifications

Verified Shop Reference Manual: KTM 250 SX-F (Engine) Repair Manual (2005-2008) Technical-Repository

Model-Designation: 250 SX-F, EXC-F, XC-F, XCF-W, SXS-F // Service-Level: Engine // Model-Designation: 2005-2008


Integrated-Framework Parameters Architecture
Engine Type Liquid-cooled, single cylinder, 4-stroke Core component
Displacement 249.51 ccm Performance metric
Ignition System Contactless DC-CDI Electrical system
Cooling System Liquid-cooled Thermal management

The documentation is partitioned into chapters covering engine disassembly, servicing of individual components, assembly procedures, and troubleshooting. This manual is designed for qualified mechanics.

Reassembly procedures are specified for all major engine components, including the crankshaft, camshafts, and transmission.

Service intervals are documented for critical engine parts to ensure longevity and optimal performance.

Component locations are identified clearly within the diagrams for ease of reference.

Service procedures are documented for routine maintenance tasks and complex repairs.

Calibration requirements are specified for systems like the throttle valve sensor and ignition timing.

This manual documents torque specifications for engine fasteners to ensure proper rotational loosening prevention.

FAQ

Determine the **specific** torque specifications for the main engine bolts. keyboard_arrow_down

6 Nm is the specified torque for checking engine mounting bolts for tightness.

What **designated** safety precautions should be followed during engine assembly? keyboard_arrow_down

When mounting the throttle valve sensor, ensure the flat spot engages the groove, and secure with Loctite 243, verifying smooth operation.

Check the **critical** lubrication requirements for the camshafts. keyboard_arrow_down

18 Nm is the tightening torque for the screws and nuts on the camshaft bearing bridge, ensuring proper lubrication.

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Reviews (3)

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The KTM 250 SX-F Repair Manual is a must-have! The download process was super smooth, and I received the link in my email almost instantly. Perfect for anyone wanting to maintain their bike properly!
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This manual has everything you need to keep your KTM 250 SX-F running like new. The customer support was fantastic—very quick to respond to my questions. Highly recommend!
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Rated 5 out of 5 stars